Forging a Full Tang Feather Damascus Knife with Integral Bolsters

In today’s video, I’m forging a full-tang feather Damascus drop point knife featuring forge-welded bolsters and handle scales made from 2,000-year-old sinker (bog) cypress. This project combines the challenge of precision forge welding with the artistry of Damascus pattern control and ancient wood finishing. Follow along as I: 🔥 Cut and draw out a custom billet of Damascus steel ⚒️ Forge weld bolsters made from 240-layer W-pattern steel 🛠️ Normalize, grind, and prep the tang and bevels 🔩 Prepare everything for final shaping and heat treat This is a customer commission build, and it’s a great example of advanced blacksmithing and bladesmithing techniques like forge welding, pattern alignment, and grain refinement. Stay tuned for the next part, where I heat treat, shape, and finish the handle! 🔗 Timestamps 0:00 Intro – Forging the feather Damascus billet 0:45 Cutting and prepping the steel 3:30 Forge welding bolsters 7:30 Test etch and pattern discussion 10:50 Welding setup & alignment 13:30 Normalizing and cleanup 15:00 Prep for drilling & beveling 16:10 Wrap-up & next video preview 🧰 Tools & Materials Feather pattern Damascus billet 240-layer W-pattern bolster stock Ancient sinker (bog) cypress Forge press, TIG welder, grinder, milling tools 💬 Join the Community If you enjoy Damascus knife making, forge welding tutorials, and custom bladesmith builds, don’t forget to: 👍 Like 🔔 Subscribe 💬 Comment below with your knife-making questions or tips! Framelock building playlist: https://studio.youtube.com/playlist/PL3J5OXaYrzvTmfsS4J46JJjspcib1MlFj/videos Knifemaking Playlist https://www.youtube.com/playlist?list=PL3J5OXaYrzvSu9Y9O1VvqcTBrFlXcrB_1 Damascus making Playlist https://www.youtube.com/playlist?list=PL3J5OXaYrzvQmX2JoRJC710cppxj7Iq2T Huge thanks to my Patrons for supporting the channel — your help keeps the forge hot! 🔥 👉 Support the channel on Patreon: https://www.patreon.com/tonyseverioknives (Below are affiliate links to products that I get a small fee at no extra cost to the buyer) YesWelder welding machines https://yeswelder.com/?ref=qkvl6voq Use CODE: TONYSEVERIO at checkout for 10% OFF! Optical Center Punch https://amzn.to/3GSLGY6 Cratex Jeweling Stick 400-600 grit https://amzn.to/47boZcR Barrel Lap set https://amzn.to/4eY47Gx Digital Angle Finder https://amzn.to/3CFWJC9 #53 Carbide Drill Bit https://amzn.to/3ZbhqhW #54 Carbide Drill Bit https://amzn.to/3Z82u4i 1/16 inch 440C ball bearings for detent https://amzn.to/3ZbiZfO 1/16 inch ceramic ball bearings for detent https://amzn.to/48UAHaI Cutoff Wheel and Arbor https://amzn.to/4eoW0T5 5/16 Carbide Ball End Mill https://amzn.to/3AL24Hv Optical Center Punch https://amzn.to/40vS3Z8 5/64 carbide drill https://amzn.to/3AhnagC #44 carbide drill https://amzn.to/3YToY9b .166 counterbore https://amzn.to/4e2hAfS #13 (.185 inches) Carbide Drill https://amzn.to/4eVfyQ3 3/16 (.1875 inches) Carbide Reamer https://amzn.to/3UmDBPi 1/8 (.125 inches) Carbide Spotting Drill 9/64 (.14 inches) Carbide End Mill 8-9 Ounce Vegetable Tanned Leather https://amzn.to/4cBGq7j Weldwood Contact Cement https://amzn.to/4lyhx06 Brown Leather Dye https://amzn.to/3GexsRe Neats Foot Oil https://amzn.to/43Tgu4F 3 piece basketweave leather stamps https://amzn.to/44cQ64i Leather stitch groover https://amzn.to/45ztTjg Leather stitch marker https://amzn.to/4lhtxSX Reading and Instruction: Knife Engineering by Dr. Larrin Thomas: https://amzn.to/3SO7hlP BUILD YOUR OWN HYDRAULIC FORGING PRESS by Dr. James Baston: https://amzn.to/3fV86L1 THANKS to my Patrons! Eric Bethard Charles Apodaca Michael Hodges Jeff Schafer Mark Anderson Allan Williams Anderson Hand Forged Michael Baker Sonja Stevenson Jeremy Green Justin Goodman James Buck Jason Mulkey Richard Branton Robert Bryant Bruce Brissette Clint Hancox Joe Dees Steve Mowatt Dave Perry Dan Still Sam Daugherty Shane Wismeyer Robert Gore George C. James Murphy Rynn Smith My Website: https://www.tonyseverioknives.com My Instagram: http://instagram.com/tonyseverioknives My Facebook: http://www.facebook.com/tonyseverioknives My TikTok: http://tiktok.com/@tonyseverioknives Rocker Chicks by Audionautix is licensed under a Creative Commons Attribution 4.0 license. https://creativecommons.org/licenses/by/4.0/ Artist: http://audionautix.com/ #customknives #bladesmithing damascus knife making, full tang knife, forge welded bolsters, feather damascus, bog cypress knife handle, blacksmithing, bladesmith, custom knife build, pattern welded steel, knife forging tutorial, how to make a damascus knife, drop point skinner, handmade knives, custom bladesmithing